Rolair JC10PLUS - Air Compressor Manual

PARTS

Genuine ROLAIR replacement parts are sold nationwide through a network of authorized dealers and service centers. Please contact the dealership where your air compressor was purchased or our factory Customer Service Department if you need help troubleshooting, obtaining parts, or locating an authorized ROLAIR service representative. You may also use the Sales and Service locator on our website www.rolair.com.

To order replacement parts:

1. Give compressor model number
2. Give compressor serial number
3. Name of part
4. Part number
5. Quantity required

RECORD OF PERTINENT
Make a permanent record of the model and serial number of your new air compressor here. You'll save time and expense by including this reference information when requesting service or replacement parts.

With the tank gauge at 0 PSI and air line(s) disconnected, close drain valve(s) and record the amount of time it takes to build tank pressure on the space provided. Periodically test your air compressor against this pumpup time to determine if it is operating correctly. If time test is considerably off, contact your local ROLAIR representative to arrange service.

*Factory top pressure settings vary. Write down the top pressure setting of your machine after performing the initial pump-up time test.

Definitions - Safety Warnings

Safety symbols are used throughout this manual to alert you to imminently hazardous and potentially hazardous situations. The following definitions describe the level of severity for each signal word.

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or damage to the air compressor, or other property.

Donotstart, operate, orservice thismachine until you read and fully understand owner's manual. Failure to do so could result in death or serious injury. If you have any questions, call us toll free at 1-800-310-3573.

CONTAINS LEAD. May be harmful if eaten or chewed. May generate dust containing lead. Wash hands after use. Keep out of reach of children.

This product can expose you to chemicals including lead, whichis known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

SAVE THESE INSTRUCTIONS!

RISK OF EXPLOSION OR FIRE

WHAT CAN HAPPEN

• Electrical components within the motor and pressure switch will spark. This is normal. If electrical sparks from the compressor come into contact with flammable vapors, they may ignite, causing fire or explosion.
• Inadequate ventilation, or restrictions to any of the compressor's ventilation openings, will cause serious overheating and could cause a fire.
• Unattended compressors with leaks in the unit or air system could start unexpectedly and repeatedly and could result in overheating, fire, and personal injury or property damage.
• A fire can occur if spilled gas or vapors come into contact with hot engine parts, lit cigarettes, or other sources of ignition.

HOW TO AVOID IT

• Always operate the compressor in a wellventilated area away from any flammable vapors, liquid, paint, gasoline, or any other combustible material.
• Always locate compressor at least 20 ft. (6.1 m) away from work area if spraying flammable materials.
• Store flammable materials in a secure location away from the compressor.
• Never place objects against or on top of an air compressor.
• Always operate air compressor at least 18" away from any wall or obstruction.
• Always operate in a clean, dry, and wellventilated area.
• Always remain in attendance with the compressor when it is operating.
• Always turn off and unplug the compressor when it is not in use.
• Never attempt to fill the gas tank while the engine is hot or running.
• Add fuel outdoors and in a well-ventilated area.
• DO not fill gas tank near lit cigarettes or near other sources of ignition.

RISK TO BREATHING (ASPHYXIATION)

WHAT CAN HAPPEN

• Air from your compressor is not safe for breathing and may contain carbon monoxide, toxic vapors, or solid particles. Serious injury or death may occur from inhaling the compressed air from your air compressor.
• Sprayed materials such as paint, stucco, insecticides, solvents, etc. may contain harmful vapors and poisons.
• For gas-powered compressors, engine exhaust fumes contain poisonous carbon monoxide which is odorless and colorless. Inhaling those fumes could lead to serious injury or death.

HOW TO AVOID IT

• Never inhale compressed air directly from the pump, tank, receiver, or breathing device connected to the air compressor.
• The compressor is not equipped with suitable filters and in-line safety equipment for human consumption. DO not use discharge air for breathing.
• Operate compressor and perform work only in a well-ventilated area. Read and follow the safety instructions provided on the label or safety data sheets for the materials you are spraying. Always use certified safety equipment designed for your specific application.
• Operate compressors only in well-ventilated areas. Avoid inhaling engine exhaust fumes, and never run a small gas-powered engine in a closed building or confined area without adequate ventilation.

RISK OF BURSTING

AIR TANK: Air tanks do not have an infinite life and should be inspected once every year to ensure they are still safe for use. To find your state pressure vessels inspector, look under the Division of Labor and Industries in the government section of a phone book or call us toll-free at 1-800-310-3573 for assistance.

The following conditions could lead to a weakening of the air tank, and result in a violent air tank explosion:

WHAT CAN HAPPEN

• Failure to properly and regularly drain condensed water from the air tanks will lead to rust and thinning of the steel air tank can lead to a violent air tank explosion.
• Modifications, alterations, or attempted repairs made to the air tank can lead to a violent air tank explosion.
• Unauthorized modifications to the safety valve, pressure switch, pilot unloader valve, or any other component which controls air tank pressure can lead to a violent air tank explosion.

HOW TO AVOID IT

• Drain tanks daily or after every 4 hours of use. If a tank develops a leak, replace it immediately with a new air tank, or new complete compressor.
• Never drill into, dent, weld, patch, or modify the air tank, or its attachments in any way. If you are in possession of a tank in which it appears any of those conditions exist or were attempted, discontinue use and replace air tank immediately.
• Never attempt to repair a damaged or leaking air tank. Replace with a new tank immediately.
• The air compressor is designed to safely operate and withstand specific factory set pressure. Never make adjustments or parts substitutions to components that control air tank pressure or factory set operating pressures.
• Do not make alterations to the factory operating pressure settings.
• Before starting, and with air tank pressure at zero, pull the ring on the safety valve to make sure it moves freely.
• Never operate without a factory approved safety valve.

Attachments & Accessories:

• Exceeding the pressure rating of air tools, spray guns, accessories, tires, or any other inflatables can cause them to explode or fly apart.
• DO not use air tools or attachments before reading the owner's manual to determine the safe maximum pressure rating.
• Never exceed the manufacturer's maximum allowable pressure ratings.
• Never use the compressor to inflate small low pressure objects such as children's toys, balls, etc.

RISK OF INJURY OR PROPERTY DAMAGE WHEN TRANSPORTING OR STORING

WHAT CAN HAPPEN

• Oil from the compressor can leak or spill and could result in fire or breathing hazard; serious injury or death can result. Oil leaks will damage carpets, paint, or any other surfaces.

HOW TO AVOID IT

• Always keep compressor level and never lay on its side. When transporting, always place compressor on a protective mat to prevent against damage from leaks. Always remove compressor from vehicle immediately upon arrival at your destination. If an oil leak is found, follow all local safety codes for cleanup of hazardous materials.

WHAT CAN HAPPEN

• Electrical Grounding: Failure to provide adequate grounding to the compressor could result in serious injury or death from electrocution.
• Your air compressor is powered by electricity. Like any electrically powered device, if it is not used properly it may cause electric shock.
• Serious injury or death can occur if repairs are attempted by unauthorized personnel.

HOW TO AVOID IT

• Always make certain that the electrical circuit to which the compressor is connected provides proper electrical grounding, correct voltage, and adequate fuse protection. If you are unsure, or have any questions about proper electrical grounding, correct voltage, or adequate fuse protection please call us toll-free at 800-310- 3573.
• Never operate the compressor outdoors when it is raining, snowing, or in wet conditions.
• Never let your electrical cord lay in water.
• Never operate the compressor with a damaged power cord, or with protective covers damaged or removed.
• Never touch plug with wet hands.
• Never pull on electric cord to disconnect from the outlet.
• Any electrical repairs or wiring performed on this compressor should only be performed by ROLAIR authorized service personnel and in accordance with all national and local electrical codes.

WHAT CAN HAPPEN

• Serious injury and property damage can occur from loose debris being propelled at high speeds from the compressed air stream.

HOW TO AVOID IT

• Always wear certified safety equipment: ANSI Z87.1 eye protection (CAN/CSA Z94.3) with side shields when using the compressor.
• Never direct the air stream, nozzle, or sprayer towards any part of your body, other people, or animals.
• Always turn off the compressor and drain tank pressure completely before attempting maintenance or attaching air hose or tools.

RISK OF HOT SURFACES

WHAT CAN HAPPEN

• Serious burn injuries can result from touching exposed metal parts such as the engine or motor, pump, or any part of the copper/braided discharge lines and components. These parts will become hot during operation and stay hot for an extended period of time even after the compressor is shut down.

HOW TO AVOID IT

• Never touch any of the exposed metal parts during operation and for an extended period of time after shut down.
• Do not reach around shrouds or attempt any maintenance until the unit has been completely cool.

RISK FROM MOVING PARTS

WHAT CAN HAPPEN

• Serious injury or death can occur if moving parts such as belts, flywheels, pulleys, or fans come into contact with you or your clothing.
• An electric air compressor can restart at any time when plugged in, and an unexpected startup can result in serious injury, death, or property damage.
• Attempting to operate the compressor with any damaged or missing parts, protective guards, shrouds, or covers will expose you to moving parts and can result in serious injury or death.

HOW TO AVOID IT

• Prior to operation, always make sure all protective guards and covers are in good condition, and never operate the compressor any guard or cover has been removed or damaged.
• Always keep your hair, jewelry, clothing, and gloves away from moving parts as they can be caught.
• It is common for air vents to cover moving parts, so they should be avoided as well.
• Always unplug the compressor when not in use.
• Always drain air tank pressure completely before attempting any repairs or maintenance.
• Never allow children or adolescents to operate the air compressor.
• Any repairs to the air compressor must only be made by ROLAIR factory authorized personnel.

RISK FROM LIFTING

WHAT CAN HAPPEN

• Serious injury can result from attempting to lift an object that is too heavy.

HOW TO AVOID IT

• Always obtain assistance from others before attempting to lift any object that is too heavy for you.

RISK OF FALLING

WHAT CAN HAPPEN

• A compressor may vibrate and move during the course of normal operation resulting in a fall from a table, workbench, roof, or other platform causing damage to the compressor, property damage, and could result in serious injury or death to anyone nearby.

HOW TO AVOID IT

• Always operate air compressor in a stable and secure position to prevent accidental movement of the unit. Never operate compressor on a roof or other elevated position. Use air hose to reach high locations.

RISK FROM NOISE

WHAT CAN HAPPEN

• Under some conditions and duration of use, noise from this product may contribute to hearing loss.

HOW TO AVOID IT

• Always wear certified safety equipment: ANSI S12.6 (S3.19) hearing protection.

RISK OF UNSAFE OPERATION

WHAT CAN HAPPEN

• Serious injury or death can occur to you or others if air compressor is used in an unsafe manner.

HOW TO AVOID IT

• Review and understand all instructions in your owner's manual.
• Know how to stop the air compressor at all times.
• DO not operate until you are thoroughly familiar with all of the controls.
• Do not operate the compressor if you are fatigued, under the influence of alcohol or drugs, or in any other state which might impair judgment.
• Stay alert while operating the compressor and pay close attention to the task at hand.

RISK OF DAMAGE TO AIR COMPRESSOR OR PROPERTY

HOW TO AVOID IT

• Check oil levels daily and maintain proper oil levels.
• Always operate compressor in a secure and level position.
• Do not operate without an air filter or in a corrosive environment.

JC1OPLUS OVERVIEW & IMPORTANT INSTRUCTIONS

The "JC10" series air compressors are low speed, oil-free direct drives designed to be extremely quiet and provide years of trouble-free service. Super thin reed valves play a major role in the quiet operation but are susceptible to damage from the ingestion of even the smallest piece of foreign material. Therefore, it is vitally important to maintain a structurally sound intake canister along with a clean and solid filter element. Replace entire intake assembly if canister breaks loose from the threaded nipple, and make a habit of checking the pleated intake element on a regular basis to make sure it remains free of holes and tears.

The next generation JC1OPLUS is redesigned with a cord wrap and built with longer cylinders that could potentially be flipped to double the service life. However, this series is not rated for 100% or continuous duty, and performs best when given as much rest as run time. If, in order to keep up, you find your compressor consistently running more than five out of every ten minutes then you'll likely need to shore up some air hose leaks or use a bigger air compressor for the job.

The motor also has automatic thermal overload protection and can restart unexpectedly and repeatedly if an overload occurs. For example, operation above the rated duty cycle due to air hose leaks. Therefore, never leave the air compressor plugged in unattended. If an overload occurs unplug and allow the compressor to cool for several hours before attempting to restart.

SYSTEM CONTROLS

1. SAFETY-RELIEF VALVE
   Every ROLAIR air compressor is equipped with a safety-relief valve which is designed to discharge tank pressure at a predetermined setting when a systems failure occurs. Check the safety valve daily by pulling on the ring only after the tank pressure has been completely drained. The spring loaded valve should move freely within the safety valve body. An inoperable safety valve could allow an excessive amount of tank pressure to build causing the air tank to violently rupture or explode. Do not tamper with or attempt to eliminate the safety relief valve.
2. AUTOMATIC INTERNAL OVERLOAD PROTECTION
   The JC series motor is built with automatic overload protection. When an electrical deficiency occurs or the compressor is operated above its rated duty cycle, the thermal protector will interrupt the power supply and automatically shut down the motor to protect it. When the motor sufficiently cools, it will attempt to restart automatically. If the electrical deficiency that caused the overload to trip is not corrected, the motor will continue to overheat and restart which may lead to a complete motor failure. Therefore, NEVER LEAVE THE AIR COMPRESSOR PLUGGED IN UNATTENDED. Always re-evaluate the power source and gauge/length of extension cord being used whenever the automatic internal thermal protector causes the motor to stop running.
3. PRESSURE SWITCH
   Your air compressor operates by the use of a pressure switch. Always make sure the lever is in the "Off" position before plugging in the power cord. By moving the lever to the "On/Auto" position, the compressor will start and stop automatically within the settings of the pressure switch which are typically 95 - 125 PSI. Do not attempt to stop the compressor by unplugging the power cord. To stop, simply move the lever to the "Off" position.
4. REGULATOR - WORKING PRESSURE
   To adjust the output/line pressure, simply rotate the regulator adjustment knob clockwise to increase working pressure or counterclockwise to decrease. Never exceed the manufacturer's maximum allowable pressure rating of the tool being used or item being inflated. Always relieve pressure from coupler by rotating adjustment knob completely counter-clockwise before removing air hose.
5. PRESSURE GAUGE(S)
   Typically, most compressors are designed with a gauge to measure tank or storage pressure and another gauge that indicates output or working pressure.

6. DRAIN VALVE(S)
   One or more drain valves are installed to allow moisture to be drained on a daily basis from the compressor storage tank(s). Open drains carefully and slowly to prevent scale. rust. or debris from becoming expelled at a high rate of speed.
7. AIR INTAKE FILTER
   An air intake filter is installed to prevent foreign material from entering the compressor pump. Check intake element on a regular basis and either clean or replace as needed. Warm soapy water or low compressed air may be used to clean the element.
8. CHECK VALVE
   Every ROLAIR air compressor is built with a check valve to seal off and maintain tank pressure after the top end pressure setting of pilot valve or pressure switch is reached. The check valve works in conjunction with the pressure switch relief valve to provide a loadless start for the compressor system. A quick burst of air escaping from the relief valve after the machine reaches top end indicates the check valve is working properly. If the compressor has a mysterious leak after stopping that cannot be traced elsewhere, the check valve may require servicing/replacing. Always drain tank pressure completely before attempting to remove or service any component.
9. VIBRATION DAMPENER(S)
   The rubber pads installed beneath every portable ROLAIR tank assembly are very important to the proper operation of the air compressor. They provide protection from vibration that left unchecked could cause damage to many system components.
10. QUICK DISCONNECT
    A universal or 3-way quick disconnect is installed on your JC series air compressor.
    Simply push a 1/4" male plug into coupler to snap hose fitting into coupler. Always relieve pressure from coupler before installing or removing hose. See instructions for regulator (#4 above). Pull back on collar to remove air hose after pressure is relieved.
11. PRESSURE SWITCH RELIEF VALVE
    A normally closed relief valve is installed on the pressure switch to provide the JC10PLUS motor with a "loadless" start. When the air compressor stops automatically, or manually using the on/off lever, the pin for the relief valve is pushed open by a paddle attached to the moveable contacts to dump off or purge head and line pressure. A noticeable burst of air must be released after the air compressor stops in order for the motor to restart at the low pressure setting of 95 PSI. If air leaks continuously from the relief valve after the compressor stops there is a problem with the proper operation of the one way tank check valve. See System Controls (Item #8). If no air is purged after the compressor stops the proper alignment of the relief valve pin and contact paddle has been compromised.

PRE-START CHECKLIST

Read the owner's manual thoroughly. Make sure that you completely understand all of the safety warnings, system controls and instructions provided before attempting to operate this air compressor. Every effort has been made to provide you with the information needed to obtain many years of reliable and trouble-free service out of your new air compressor. It is your responsibility to operate the air compressor properly. To obtain the longest possible service life from your air compressor you must always keep the following instructions in mind.

1. INSTALL AIR INTAKE FILTER
   Remove metal air cleaner assembly from the bag attached to the compressor with owner's manual. Thread intake filter into open port on pump cylinder head. Reference #7 on the System Controls drawing or review schematic and/or picture on box for proper location to install air cleaner.
2. OPERATE IN A CLEAN DRY AND WELL VENTILATED AREA
   Allow at least 18" behind the belt guard for proper cooling of pump from flywheel blast. Do not operate in the rain or in areas of standing water. Never operate in an area where other gases, fumes or vapors are present which may become explosive when compressed. Do not operate compressor in an enclosed area or with any of the ventilation openings covered.

Power Cord
A/B Plug Type
60 Hz, 120 V
This product is for use on a 120-volt circuit and should be grounded. A cord with a grounding plug as illustrated must be used. No adapter should be used with this product.

5. DO NOT USE A GENERATOR AS THE POWER SOURCE
   Air compressors use inductive motors that require 3-5 times the full-load amp draw to properly start. Most generators will not provide the wattage needed to properly start this type of electric motor.
6. CHECK TENSION OF BOLTS BELTS AND HARDWARE ON A REGULAR BASIS
   Operation of any equipment with loose bolts and/or fittings will lead to excessive vibration and the premature failure of the compressor system control components.
7. MAINTAIN RUBBER VIBRATION PADS
   Excessive vibration is a major cause of premature compressor failure. Always maintain the rubber vibration pads located beneath tank assembly. Operation without them will void your warranty.
8. DRAIN MOISTURE FROM AIR TANK DAILY
   Water is a natural byproduct of compressed air. Drain air tank(s) after each use to combat internal tank corrosion. Keep drain valve(s) closed if storing compressor for any length of time.

HIGH-ALTITUDE OPERATION:
Due to a decrease in atmospheric pressure air compressor pumps produce less CFM at higher elevations. As a rule of thumb the output will decrease approximately three percent per 1000 feet of elevation. Also, because air at higher elevations is less dense and does not cool as well, electric motors cannot be subjected to the full nameplate service factor amp rating and may need to be upgraded to avoid repeated overheating.

Direct drive or hand-carry compressors built with cold-start valves may need to be modified when operated in higher elevations. Contact our factory Customer Service Department if your normally reliable air compressor fails to operate correctly at higher elevations.

MAINTENANCE

Your new air compressor represents the finest engineering and construction available. Even the best machinery requires periodic maintenance. Please stick to the maintenance schedule and consider the suggestions that follow to keep your compressor in peak condition.

NOTE: Always unplug or shut down your compressor and drain the air tanks completely before attempting any type of maintenance. Wait for compressor to cool before servicing.

MAINTENANCE HINTS:

1. Use a soap/water solution to check for air leaks.
2. Never clean filters with a flammable solvent.
3. Retorque head bolts only after pump has cooled.
4. Never weld on air tank(s).
5. Use heat to loosen Loctite seal on drains and other fittings before attempting to remove.

MAINTENANCE RECORD
Routine maintenance is your responsibility and necessary to maximize the life of your new compressor. Please record your maintenance activities in the chart below and take this information with you if warranty service is required.

TROUBLESHOOTING

Make sure you completely understand all of the safety warnings and operation of each system control component before attempting any maintenance or repair. Always drain the tank pressure completely, make sure the power cord is unplugged, and unit has time to cool before performing any maintenance or service operations.

If after reading this manual you have any questions whatsoever on the proper installation, operation, or maintenance of your air compressor please feel free to contact our Customer Service Department at 1-800-310-3573.

606 South Lake Street > P.O. BOX346 > Hustisford, WI 53034-0346 > 920.349.3281 > fax 920.349.8861 > www.rolair.com

Documents / Resources

References

• Rolair Systems - Air Compressors
• http://www.p65warnings.ca.gov

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